OK I have a front shackle that has apparently been bent recently. I need to have a set made up frt/rr but am not sure what size to go to. The factory stampings are puny compared to anything in the aftermarket..... should i go 1/4" or 3/8" thick steel stock? and should I go with 1.5" or 2" wide? And then what length? I have stock springs and would like to gain a bit if I am putting new shackles in anyways....... stock is about 4" hole-to-hole I think, so would stretching that to 6" for about an inch net lift be too much? I don't want to loose too much Caster angle in front. And I was thinking about welding and/or bolting a brace for an "H" style for better road manners around corners, currently I have a drivers side shackle/spring eye leaning to the left and I suspect it's moving to some extent when driving around. As always I need to do this myself to save some non-existent money. I Really appreciate the opinions of the more experienced guys than me on the forum! 
Most shackles use two plates so width does not matter at all. Only some aftermarket shackles use the H design. H design is used to stiffen the taller shackles BUT does hinder movement. If you're going to stick with stock height then get some 3/8's punch two holes and you're done. Stock leaf width is 2.5". Stock length is 4". Keep in mind for every increase in length, you only make half that in height. Also keep in mind that 1.25" Lift (7" Total) is the MAX and you probably shouldn't go near that with stock leafs. 3/8" lift or .5" lift would be ok if you want a bit more though.
My front shackles are custom made from 3/8" stock punched out on an iron worker, I believe. Pretty simple.
